Apparatus, systems, and methods for purifying a fluid with a silicon carbide membrane

ABSTRACT

The present disclosure relates, according to some embodiments, to systems, apparatus, and methods for fluid purification (e.g., water) with a ceramic membrane. For example, the present disclosure relates, in some embodiments, to a cross-flow fluid filtration assembly comprising (a) membrane housing comprising a plurality of hexagonal prism shaped membranes (b) an inlet configured to receive the contaminated fluid and to channel a contaminated fluid to the first end of the plurality of hexagonal prism shaped membranes, and (c) an outlet configured to receive a permeate released from the second end of the plurality of hexagonal shaped membranes. The present disclosure also relates to a cross-flow fluid filtration module comprising a fluid path defined by a contaminated media inlet chamber, a fluid filtration assembly positioned in a permeate chamber and a concentrate chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/258,274 filed on Nov. 20, 2015. The contents of the aboveapplication is hereby incorporated in its entirety by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates, in some embodiments, to apparatus,systems, and methods for decontaminating a fluid (e.g., water) with aceramic membrane.

BACKGROUND OF THE DISCLOSURE

Since almost all forms of life need water to survive, the improvement ofwater quality in decontamination systems has typically been a subject ofsignificant interest. As a result, treatment systems and techniques forremoving contaminants from contaminated fluids have been developed inthe past. Approaches include water treatment by applying variousmicroorganisms, enzymes, and nutrients for the microorganisms in water.Other approaches involve placing chemicals in the contaminated fluids,such as chlorine, in an effort to decontaminate supplies. Theseadditives can, however, create more problems than they solve. Someapproaches avoid the use of added chemicals or microorganisms by using afiltration and/or irradiation strategy. Such systems have either failedor failed to realize their potential, such that challenges remain.

SUMMARY

Accordingly, a need exists for improved fluid purification. For example,a need exists for fluid purification apparatus, systems, and methodsthat display improved transmembrane pressure performance.

The present disclosure relates, according to some embodiments, to aceramic membrane that may comprise: a substrate configured to have afirst surface, a second surface, and body; a binder; a first membranelayer on at least a portion of the first surface of the membrane; and asecond membrane layer on at least a portion of the second surface of themembrane; and a third membrane layer on at least a portion of the bodyof the membrane, wherein the membrane may be configured to have a cleanwater flux of about 2000 liters per hour per square meter of membranesurface area at a transmembrane pressure of about 20 psi or less. Asubstrate may comprise a substance selected from the group consisting ofalumina, zirconium dioxide, titanium dioxide, silicon carbide. A systemmay be configured to have a transmembrane pressure of about 20 psi orless at about 20° C. A binder may comprise a substance selected from thegroup consisting of tylose, polyvinyl acetate, polypropylene, sodiumpolyacrylate, polypropylene carbonate, carboxymethylcellulose, starches,polyvinyl alcohol, dextrin, wax emulsions, polyethylene glycols,lignosulfonates, paraffins, sodium silicate, magnesium aluminumsilicates, and bentonite. A substrate may have an average pore size fromabout 3 μm to about 10 μm. A ceramic membrane may have a vertex tovertex diameter from about 38 mm to about 90 mm. A ceramic membrane maybe a hexagonal prism. A ceramic membrane may have a vertex to vertexdiameter of about 80 mm. A ceramic membrane may have a length from about800 mm to about 1600 mm. A first membrane layer may comprise a substanceselected from the group consisting of alumina; zirconium dioxide;titanium dioxide; or silicon carbide. A second membrane layer maycomprise a substance selected from the group consisting of alumina;zirconium dioxide; titanium dioxide; or silicon carbide. A thirdmembrane layer may comprise a substance selected from the groupconsisting of alumina; zirconium dioxide; titanium dioxide; or siliconcarbide. In some embodiments, up to three coats of a first membranelayer may be contacted to at least a portion of a first surface of themembrane. Up to three coats of a second membrane layer may be contactedto at least a portion of a second surface of the membrane. Up to threecoats of a third membrane layer may be contacted to at least a portionof a body of the membrane.

In some embodiments, the present disclosure relates to a method ofmaking a ceramic membrane may comprise: extruding a substrate materialto form a length of extruded membrane having at least a first surface, asecond surface, and a body; drying an extruded membrane substrate toform a ceramic membrane substrate; contacting a first membrane layer toat least a portion of the first surface; contacting a second membranelayer to at least a portion of the second surface; and contacting athird membrane layer to at least a portion of the body. A substratematerial may comprise a binder and a substrate base. A substrate basemay comprise a substance selected from the group consisting of alumina,zirconium dioxide, titanium dioxide, silicon carbide. A binder maycomprise a substance selected from the group consisting of tylose,polyvinyl acetate, polypropylene, sodium polyacrylate, polypropylenecarbonate, carboxymethylcellulose, starches, polyvinyl alcohol, dextrin,wax emulsions, polyethylene glycols, lignosulfonates, paraffins, sodiumsilicate, magnesium aluminum silicates, and bentonite. A membrane layermay comprise a substance selected from the group consisting of alumina,zirconium dioxide, titanium dioxide, silicon carbide. A first membranelayer may comprise a substance selected from the group consisting ofalumina; zirconium dioxide; titanium dioxide; or silicon carbide. Asecond membrane layer may comprise a substance selected from the groupconsisting of alumina; zirconium dioxide; titanium dioxide; or siliconcarbide. A third membrane layer may comprise a substance selected fromthe group consisting of alumina; zirconium dioxide; titanium dioxide; orsilicon carbide. A substrate material may have an average pore size fromabout 3 μm to about 10 μm. A ceramic membrane may be a hexagonal prism.A hexagonal prism may have a vertex-to-vertex diameter from about 38 mmto about 90 mm. A ceramic membrane may have a length from about 800 mmto about 1600 mm.

According to some embodiments, a fluid filtration system may comprise: amembrane housing, the membrane housing comprising: (a) an inletconfigured to receive a contaminated fluid; (b) a plurality of membranesconfigured to filter the contaminated fluid to form a permeate, whereineach of the plurality of membranes may comprise: a first end configuredto receive the contaminated fluid; a second end configured to releasethe permeate; a length extending between the first and the second end;and at least one channel oriented along a longitudinal axis from thefirst end to the second end; (c) a connector adjacent to the inlet andconfigured to channel the contaminated fluid to the first end of theplurality of membranes; and (d) an outlet configured to receive thepermeate released from the second end, wherein the membrane housingencloses the plurality of membranes such that the length of theplurality of membranes may be substantially parallel to a longitudinalaxis of the membrane housing. In some embodiments, a plurality ofmembranes further may comprise: a substrate; and a ceramic materialforming a membrane. A substrate may comprise a substance selected fromalumina, zirconium dioxide, titanium dioxide, or silicon carbide. Aplurality of membranes further may comprise a ceramic coating comprisinga substance selected from alumina, zirconium dioxide, titanium dioxide,or silicon carbide. Each membrane of the plurality of membranes may be ahexagonal prism. A hexagonal prism may comprise a vertex-to-vertexdiameter between about 38 mm to about 90 mm. In some embodiments, atleast one channel may comprise a shape selected from circle, square,triangle, trapezium, diamond, rhombus, parallelogram, rectangle,pentagon, hexagon, octagon, nonagon, oval, or hexagon. A section of theat least one channel defines a circle having a diameter from about 4 toabout 6 mm. A membrane housing may comprise up to about 171 membranes. Amembrane housing may comprise from about 1 to about 200 membranes. Amembrane housing may comprise about 30 to about 40 membranes. In someembodiments, an effective membrane surface area may be from about 0.5 m²to about 600 m².

According to some embodiments, a method for filtering fluid may comprisea soluble or insoluble contaminant and a fluid, the method comprising:flowing contaminated fluid from the fluid inlet end of a membranehousing comprising a plurality of hexagonal prism shaped membranes tothe fluid outlet end of the membrane housing, wherein the permeate maybe released from the membrane housing.

A contaminated fluid filtration system comprising: a membrane casing anda plurality of membranes; at least one about 800 mm to about 1600 mmlength hexagonal prism shaped membrane for filtering a contaminatedfluid that receives the contaminated fluid at a proximal end andreleases a permeate at a distal end; at least one hexagonal prism shapedmembrane with a vertex-to-vertex diameter of about 80 mm; a membranecount from about 29 to about 43; at least one membrane without apermeate channel; a binder; and an effective membrane surface area ofabout 110 m² to about 165 m², wherein the system may be configured tohave a clean water flux of about 2000 liters per hour per square meterof membrane surface area at a transmembrane pressure of about 20 psi orless at about 20° C.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the disclosure may be understood by referring, inpart, to the present disclosure and the accompanying drawings, wherein:

FIG. 1A illustrates a cross-sectional view of a cylindrical ceramicmembrane, according to a an example embodiment of the disclosure;

FIG. 1B illustrates a cross-sectional view of a hexagonal prism shapedceramic membrane, according to a an example embodiment of thedisclosure;

FIG. 2A illustrates a perspective view of a cylindrical ceramicmembrane, according to a an example embodiment of the disclosure;

FIG. 2B illustrates a perspective view of a hexagonal prism shapedceramic membrane, according to a an example embodiment of thedisclosure;

FIG. 3 illustrates a perspective view of a purification module,according to a an example embodiment of the disclosure;

FIG. 4 illustrates a perspective view of a permeate chamber with engagedceramic membrane, according to a an example embodiment of thedisclosure;

FIG. 5A illustrates a perspective view of a permeate chamber with 171engaged ceramic membranes, according to a an example embodiment of thedisclosure;

FIG. 5B illustrates a perspective view of a permeate chamber with 36engaged ceramic membranes, according to a an example embodiment of thedisclosure;

FIG. 6A illustrates a cross-sectional view of a permeate chamber with171 engaged ceramic membranes, according to a an example embodiment ofthe disclosure;

FIG. 6B illustrates a cross-sectional view of a permeate chamber with 36engaged ceramic membranes, according to a an example embodiment of thedisclosure; and

FIG. 7 illustrates a perspective view of a cylindrical ceramic membrane,according to a an example embodiment of the disclosure.

TABLE 1 FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. FIG. 1A 1B 2A2B 3 4 5A 5B 6A 6B 7 Ceramic Element 150 150 730 Channel 151 151 250 250740 Filtration Layer Outer Membrane 252 252 Substrate 153 153 253 253Face 154, 156 154, 156 251 251 Side 155 155 Purification Module 320Contaminated 322 Media Chamber Inlet 324 Contaminated 326 Media ChamberBody Flange 328 Permeate Chamber 330 430 530 530 Flange 331 431 531 531630 630 Permeate Chamber 332 432 532 532 631 631 Body Outlet 333 433 533533 633 633 Ceramic Element 440 540 540 640 640 Assembly Concentrate 360Chamber Permeate Channel 731

Specific Example Embodiments

Example embodiments of a ceramic membrane are illustrated in FIG. 1A.Ceramic element 150 comprises channels 151, substrate 153, first face154, and elongate sides 155. Ceramic element 150 does not include afiltration layer. As shown, ceramic element 150 has a generally circularcross section with generally circular channels 151. Channels 151extended through ceramic element 257 of FIG. 2A along its length. FIG.1A illustrates a section view of element 150, the section generallyperpendicular to the element's longitudinal axis. Channels 151, asillustrated may have a relatively small diameter (e.g., smaller thanchannels 250 of FIG. 2A) affording fluid a greater distance of substrate153 through which to pass before reaching the element's permeate side.Example embodiments of a ceramic membrane are illustrated in FIG. 1B.Ceramic element 150 comprises channels 151, substrate 153, first face154, and elongate sides 155. Ceramic element 150 does not include afiltration layer. As shown, ceramic element 150 has a generallyhexagonal cross section with generally circular channels 151. Channels151 extended through ceramic element 257 of FIG. 2B along its length.FIG. 1B illustrates a section view of element 150, the section generallyperpendicular to the element's longitudinal axis. Channels 151, asillustrated may have a relatively small diameter (e.g., smaller thanchannels 250 of FIG. 2B) affording fluid a greater distance of substrate153 through which to pass before reaching the element's permeate side.

Example embodiments of a ceramic membrane are illustrated in FIGS. 2Aand 2B. In FIG. 2A, ceramic element 257 comprises channel 250, elongateside 255, first face 251, second face 256, and substrate 253. As shown,ceramic element 257 has a generally circular cross section withgenerally circular channels 250. Channels 250 extend through ceramicelement 257 along its length. A filtration layer 252 is positioned oversubstrate 253. Outer filtration layer extends from first face 251, alongthe sides as well as completely covering the inner surface of eachchannel 250.

DETAILED DESCRIPTION

The present disclosure relates, in some embodiments, to systems,apparatus, and methods for fluid purification (e.g., chemical-freepurification). In some embodiments, the present disclosure relates tosystems, apparatus, and methods for fluid filtration (e.g., water). Forexample, a system for fluid filtration may comprise a contaminated mediastream, a purification module, a permeate stream, and combinationsthereof. A system optionally may comprise a concentrate stream, one ormore pumps, one or more valves, one or more compressed gas sources, oneor more storage tanks, and combinations thereof. A concentrate streammay have a higher concentration of one or more contaminants than acorresponding contaminated media feed, for example, because of volumelost as permeate. In some embodiments, permeate may be collected as afinished product or subjected to further purification measures. Aconcentrate stream may be collected as a final water product orsubjected to further purification measures. Additional purificationmeasures may include, for example, oxidation, ultraviolet irradiation,photo-catalysis, filtration, and combinations thereof. For example, aconcentrate stream may be filtered more than once using the same oranother filter. A concentrate stream to be recycled through the samefilter may or may not be combined with naïve contaminated media. In someembodiments, the present disclosure relates to a method of filteringfluid comprising a soluble or insoluble contaminant and a fluid, themethod comprising flowing contaminated fluid from the fluid inlet end ofa membrane housing comprising a plurality of hexagonal prism shapedmembranes to the fluid outlet end of the membrane housing, wherein thepermeate is released from the membrane housing.

In some embodiments, systems, and methods may include at least oneceramic element that may provide both size filtration and chargeadsorption. Unlike reverse osmosis, ceramic membranes may advantageouslybe cleaned with aggressive chemicals (e.g., hydrochloric acid, nitricacid, sodium hydroxide, sulfuric acid) and may have a usable life ofmore than 25 years. Further, a concentrate stream containing chargedparticles (e.g., brine) may be more concentrated than, for example,existing Total Dissolved Solids (TDS) removal technologies. In someembodiments, systems, and methods (e.g., crossflow operation) mayadvantageously have less (e.g., substantially less) fouling incomparison to reverse osmosis membranes. In some embodiments, operatingcosts may be lower (e.g., substantially lower) than other desalinationtechnologies (e.g., electro-dialysis reversal and/or reverse osmosis).High surface area (e.g., extremely high surface area) of purificationsubstrates may provide high capacity for charge removal before substratedesorption is required or desired. Other types of ceramic substrates(e.g., zinc oxide, silicon carbide, titanium carbide, barium titanate)may have increased or decreased electrical conductivity and may be moreefficient by providing greater charges.

Fluid Filtration System

The present disclosure relates, in some embodiments, to filtrationsystems. For example, a filtration system may comprise a contaminatedmedia chamber having an inlet to admit contaminated media and an endplate, the end plate comprising a plurality of frusto-conical openings;a permeate chamber having a cylindrical body and an end plate at eachend, each end plate comprising a plurality of frusto-conical openings,and/or a filtration assembly in fluid communication with both acontaminated media chamber and a permeate chamber. A filtration modulemay comprise, according to some embodiments, a membrane housing and aplurality of membranes, wherein each of the plurality of membranesconfigured as a hexagonal prism comprising a first end configured toreceive a contaminated fluid, a second end configured to release apermeate, a length, and at least one channel oriented along alongitudinal axis from the first to the second end and configured tofilter the contaminated fluid to form the permeate; and wherein themembrane housing encloses the plurality of membranes such that thelength of the plurality of membranes substantially parallel to alongitudinal axis of the membrane housing, wherein the membrane housingcomprises an inlet configured to receive the contaminated fluid, aconnector adjacent to the inlet and configured to channel thecontaminated fluid to the first end of the plurality of membranes, andan outlet configured to receive the permeate released form the secondend. A fluid filtration system, wherein the plurality of membranes mayfurther comprise a substrate, a ceramic material, and a binderconfigured to adhere the ceramic material prior to drying and firing theceramic.

A ceramic element may be in fluid communication with a contaminatedmedia chamber and/or a permeate chamber. According to some embodiments,a contaminated media chamber (e.g., a contaminated media chamber cavity)may be in fluid communication with a permeate chamber ((e.g., a permeatechamber cavity) via a ceramic element. According to some embodiments, aceramic element may engage a contaminated media chamber interface and/ora permeate chamber interface. A gasket may include a body configured toform a fluid-tight (e.g., liquid-tight) seal (e.g., a triple seal)restricting or preventing fluid flow from a contaminated media chamberto a permeate chamber except through a ceramic element. For example, agasket may form a seal between a contaminated media chamber and apermeate chamber, between a contaminated media chamber and theenvironment, between the environment and the permeate chamber, between acontaminated media chamber and the permeate chamber-facing surface of aceramic element, between a contaminated media chamber end plate and apermeate chamber end plate, and/or between a (e.g., each) frusto-conicalopening of a contaminated media chamber end plate and a (e.g., each)frusto-conical opening of a permeate chamber end plate.

According to some embodiments, fluid filtration system may be designedto regulate transmembrane pressure (TMP), or the pressure that may beneeded to press at least a portion of a fluid through at least a portionof a membrane. In some embodiments, TMP may be a pressure gradient of amembrane and/or an average feed pressure minus a permeate pressure. Insome embodiments, a system may include at least one hexagonal prismshaped membrane (e.g., about 800 mm to about 1600 mm in length). Ahexagonal prism shaped membrane may have a vertex to vertex diameter ofabout 80 mm. A hexagonal prism shaped membrane may have a permeatechannel. At least one of the hexagonal prism shaped membranes may nothave a permeate channel. A fluid filtration system may comprise amembrane count of about 29 to about 43 membranes. A hexagonal prismshaped membrane may comprise a binder to adhere the ceramic materialprior to drying and/or firing. A fluid filtration system may comprise aneffective membrane surface area of about 110 m² to about 165 m². A fluidfiltration system may comprise an effective membrane surface are fromabout 0.5 m² to about 600 m². In some embodiments, a fluid filtrationsystem may be configured to have a clean water flux of about 2000 litersper hour per square meter of membrane surface area (“LMH”)

Contaminated Media Chamber

A contaminated media chamber may comprise, in some embodiments, an inletand a ceramic membrane interface, according to some embodiments. Acontaminated media chamber may comprise an interior cavity. An interiorcavity may have any desired size and/or any desired shape. For example,a cavity may have a rounded and/or generally dome shape. A contaminatedmedia chamber may have an outer perimeter and/or circumference. In someembodiments an outer perimeter and/or circumference may be configured asand/or define a contaminated media chamber flange. A contaminated mediachamber flange may be configured to engage a permeate chamber (e.g., apermeate chamber comprising a similar or mated flange). In someembodiments, a contaminated media chamber flange may comprise a channelfor a gasket, O-ring, or other seal. A contaminated media chamberchannel may be positioned on one face of a flange and/or substantiallyparallel to an outer perimeter and/or circumference in some embodiments.

According to some embodiments, a contaminated media chamber may have oneor more inlets and/or one or more outlets. For example, a contaminatedmedia chamber may have a ceramic element interface comprising one ormore outlets. Each outlet may be configured to engage a ceramic element,for example, with a substantially fluid-tight seal. In some embodiments,an outlet may have any desired shape (e.g., cylindrical, conical,frusto-conical). All contaminated media chamber outlets may bepositioned in an interface and/or inside a contaminated media chamberchannel.

A concentrate chamber may have a structure corresponding to acontaminated media chamber and be configured to receive concentrateflowing out of each ceramic element. For example, a concentrate chambermay have a cavity, an outlet, and/or a ceramic element interfacecomprising at least one aperture (e.g., at least one frusto-conicalaperture).

A contaminated media chamber and/or a concentrate chamber may have anydesired dimensions. According to some embodiments, a contaminated mediachamber and/or a concentrate chamber may have a length from about 10 cmto about 150 cm, from about 20 cm to about 100 cm, from about 15 cm toabout 75 cm, and/or combinations thereof. A section taken perpendicularto a chamber's longitudinal axis may have a longest dimension (e.g.,diagonal or diameter) from about 2 cm to about 30 cm in diameter, fromabout 2 cm to about 20 cm in diameter, from about 5 cm to about 20 cm indiameter, from about 5 cm to about 15 cm in diameter, from about 10 cmto about 45 cm in diameter, and/or combinations thereof. The shapeand/or dimensions of a contaminated media chamber and a concentratechamber may be the same or different.

Permeate Chamber

The present disclosure relates, in some embodiments, to a permeatechamber comprising a ceramic element interface, an interior permeatecavity, and a permeate outlet in fluid communication with the interiorpermeate cavity. A permeate chamber may have any desired shape. In someembodiments, a permeate chamber may have a generally cylindrical shapedefining a central longitudinal axis and a cavity spanning its length.For example, up to all sections perpendicular to a central permeatechamber axis may have a generally annular shape. A permeate chamber mayhave a hollow, generally cylindrical shape, a first end and a second endaccording to some embodiments. Each end may define an aperture sizedand/or shaped to receive a ceramic element interface.

A permeate chamber may have any desired dimensions. According to someembodiments, a permeate chamber may be from about 10 cm to about 5 mlong, from about 50 cm to about 5 m long, from about 1 m to about 3 mlong, and/or combinations thereof. A section taken perpendicular to thelongitudinal axis may have a longest dimension (e.g., diagonal ordiameter) from about 2 cm to about 30 cm in diameter, from about 2 cm toabout 20 cm in diameter, from about 5 cm to about 20 cm in diameter,from about 5 cm to about 15 cm in diameter, from about 10 cm to about 45cm in diameter, and/or combinations thereof.

Ceramic Element

Fluid communication between a contaminated media chamber and a permeatechamber may be mediated by a ceramic element. For example, at least somefluid may flow through an inlet into a contaminated media chambercavity, through a contaminated media chamber cavity into a ceramicelement, through a ceramic element into a permeate cavity, and/orthrough a permeate cavity and out through a permeate outlet. A ceramicelement may comprise, according to some embodiments, a filter and atleast one seal gasket. A seal gasket may be configured to limit fluidmovement between a contaminated media chamber and a permeate chamber topassage through a filter (bypass). For example, a ceramic element mayinclude a seal that partially, substantially completely, or completelyprevents fluid bypass.

A ceramic element may be configured to operate in any desired manner.For example, a ceramic element may be configured for dead-end orcrossflow operation. An elongate element may define an interior channelwith a longitudinal axis, in some embodiments. A crossflow purificationmodule may include a ceramic element comprising an elongate channelconfigured such that the element's longitudinal axis is generallyparallel to the direction of contaminated media flow and permeate flowis generally radially outward from the longitudinal axis.

In some embodiments, an element may have a wall defining an elongatebody having at least one interior channel. An element may comprise acontaminated media-facing surface and a permeate facing surface, in someembodiments. For example, an element may define an elongate body havingat least one interior surface (e.g., a contaminated media-facingsurface), at least one interior channel, and an exterior surface (e.g.,a permeate chamber facing surface). Contaminated fluid may enter atleast one interior channel at one end and flow down the length of anelement. As it travels along a channel, some fluid may traverse anelement wall and form permeate. Some fluid (e.g., a reject stream) maypass all the way along the longitudinal axis of the interior channel andout the distal end.

Ceramic Membrane

A ceramic membrane (also called an element) may comprise, according tosome embodiments, a filter of any desired size, shape, or composition.For example, a ceramic membrane may be shaped like a prism comprising ashape selected from a triangular prism, rectangular prism, square prism,pentagonal prism, hexagonal prism, heptagonal prism, octagonal prism,nonagonal prism, or decagonal prism. For example, the prism may comprisea vertex-to-vertex diameter between about 38 mm to about 90 mm. A fluidfiltration system comprising a membrane housing and a plurality ofmembranes, comprising from about 1 membrane to about 171 membranes. Afluid filtration system may comprise from about 1 membrane to about 200membranes. For example, a ceramic element may comprise a generallytubular filter (e.g., a ceramic filter). A ceramic element may includeany desired filter or filter material. For example, a ceramic elementmay comprise a filter having one or more organic polymers and/or one ormore ceramic materials. Examples of filters (e.g., ceramic membranes)may include microfiltration filters, ultrafiltration filters,nanofiltration filters, antimicrobial filters, maintenance-free filters,and combinations thereof. A filter may comprise an antimicrobial agent.For example, a ceramic filter may comprise silver (e.g., an impregnated,non-leachable silver). In some embodiments, a ceramic element mayexclude a filter e.g., where the element adsorbs ions).

In some embodiments, ceramic filters may be durable (e.g., more durablethan organic polymer filters). For example, ceramic filters may beresistant to mechanical damage, solvents, and/or microbes. Examplemetrics of performance and/or resistance may be the degree of filtrationprovided for one or more contaminants, conductivity, usable lifespan,and/or combinations thereof. Desired performance and/or resistance maybe expressed as a fraction (e.g., percentage) compared in the presenceor absence of challenge, relative to another membrane, or against athreshold or target value.

In some embodiments, a ceramic membrane may comprise a ceramic element(i.e., base) and a filter layer (e.g., ceramic coating). For example, aceramic membrane may comprise a ceramic coating having smaller pores,wherein the ceramic coating comprises alumina; zirconium dioxide;titanium dioxide; or silicon carbide. In some embodiments, multipleceramic coatings may be applied, wherein the coatings comprise agradient of pore sizes. The number of ceramic coatings or filter layersmay depend on a desired pore size (i.e., each layer or coat being asmaller or larger pore size). A gradient of pore size may prevent alayer from falling into a substrate or membrane layer with a larger poresize. An underlying base or substrate may have larger pores. In someembodiments, a substrate may comprise alumina, zirconium dioxide,titanium dioxide, or silicon carbide. Varying combinations of substrateand ceramic coating compositions may advantageously allow control ofceramic membrane flow rates, which may increase or decreasetransmembrane pressure. A ceramic membrane may include a filter layeronly inside the channels and an epoxy coating sealing the end face. Aceramic membrane may have at least one channel, defined in the wall, andwherein the channel permits fluid to move from the fluid inlet to thefluid outlet while adsorbing a contaminant and desorbing the permeate.According to some embodiments, a filtration layer may instead cover aninterior surface, an end face, and/or an exterior surface. For example,a filtration layer may define, be coextensive with, and/or cover acontaminated media facing surface of an element. A ceramic filtrationlayer may line the interior surface (e.g., channels), wrap around theface of the element, and extend a portion of the way down the outside ofthe element (at each end). A base may define, be coextensive with,and/or cover a permeate facing surface.

An elongate ceramic element may have a cross-section (e.g., a sectionperpendicular to the central longitudinal axis) with any desired regularor irregular geometric shape. For example, an element cross-section mayhave a shape selected from generally circular, generally elliptical,generally polygonal (e.g., hexagonal), and/or combinations thereof. Anelongate element may have a central axis with one or more channels alongthe length of the element and generally parallel to the axis. A channelmay comprise different shapes. For example, the channel cross-sectionalshape comprises a shape selected from circle, square, triangle,trapezium, diamond, rhombus, parallelogram, rectangle, pentagon,hexagon, octagon, nonagon, oval, or hexagon. For example, the channelshape may comprise a circle with a diameter from about 4 mm to about 6mm.

A ceramic element may have any desired dimensions. According to someembodiments, an elongate element may be from about 900 to about 1500 mmlong, about 10 cm to about 5 m long, from about 50 cm to about 5 m long,from about 1 m to about 3 m long, and/or combinations thereof. A sectiontaken perpendicular to the longitudinal axis (e.g., “diameter”) may befrom about 2 cm to about 30 cm in diameter, from about 2 cm to about 20cm in diameter, from about 5 cm to about 20 cm in diameter, from about 5cm to about 15 cm in diameter, from about 10 cm to about 45 cm indiameter, and/or combinations thereof. An element may comprise one ormore longitudinal channels. For example, an element may have about 37channels arranged in about 7 rows with from about 4 to about 7 channelsin each row. An element may have about 19 channels arranged in about 5rows with from about 3 to about 5 channels in each row. An element mayhave channels arranged in a concentric polygonal pattern. Each channelmay independently have any desired shape and/or dimension. In someembodiments, a channel may have a generally circular shape with a radiusfrom about 1 mm to about 15 cm, from about 2 mm to about 10 cm, fromabout 5 mm to about 5 cm, from about 1 cm to about 5 cm, and/orcombinations thereof.

Element channels and pores may be distinguished, according to someembodiments, on the basis of size, geometry, and/or function. Forexample, pores may be one or more orders of magnitude smaller thanchannels (e.g., from about 2 to about 10 orders smaller), may define anirregular (e.g., convoluted) flow path, and/or admit only moleculesbelow a threshold size. Channels may be one or more orders of magnitudelarger than pores, define a regular flow path, and/or admit all orsubstantially all of a contaminated media (e.g., fluid, suspendedparticles, and dissolved materials).

A ceramic element, according to some embodiments, may comprise a filterand a substrate. A membrane filter may be applied to a substrate andline each of its channels. A portion of the fluid that flows into eachchannel passes through the membrane under the influence of backpressure. Contaminants remain inside the channels, and the cleaned fluidflows through the membrane and then through the substrate. In someembodiments, a majority of a ceramic element may comprise substratematerial.

A ceramic element (e.g., a substrate) may comprise up to about 100%(w/w) silicon carbide. Silicon carbide (SiC) is a semi-conductormaterial, meaning that it has electrical conductivity that ranks betweenthat of an insulator and a metal. A semiconductor may change itselectrical conductance with the addition of a dopant. For SiC, dopantswhich increase electrical conductivity may include, for example, boron,aluminum and nitrogen.

A ceramic element may be configured, in some embodiments, to selectivelyfilter a fluid with respect to the sizes of the solids (e.g., dissolvedsolids, suspended solids) present. For example, a ceramic element mayinclude a membrane having pores sized to separate, exclude, and/orremove contaminants (e.g., particles) on the basis of their size.According to some embodiments, a ceramic element may be configured toseparate, exclude, and/or remove contaminants with respect to theircharge. For example, a ceramic element may be configured to reduce thenumber of charged contaminants in a fluid (e.g., a contaminated media, apermeate produced in a prior purification step).

A ceramic element may be configured and operated such that chargedcontaminants in a fluid (e.g., a contaminated media) adhere tooppositely charged components within the ceramic element. Adhesionbetween these contaminants and the ceramic element may be sufficientlystrong to prevent passage of at least some of the charged particles intothe permeate. An electrical current may be applied to a ceramic element,for example, sufficient to instill a net negative charge at the membranesurface.

A ceramic element may have a high (e.g., an extremely high) surfacearea, in some embodiments. Increasing the length of the membrane toabout 1500 mm may increase the surface area to about 50% more surfacearea in comparison to membranes shorter than about 1500 mm. Someembodiments may have no permeate channels, which may increase surfacearea. The capacity of a ceramic element to absorb charged contaminantsmay be correlated with surface area.

In some embodiments, adsorption (e.g., species and/or capacity) may beinfluenced by the distance of substrate through which a fluid passes toreach the permeate side of the element. For example, adsorption capacityof an element having narrow-diameter channels may be greater than anelement having wider channels (e.g., assuming the two elements have thesame or substantially the same outer dimensions and number of channels).Adsorption capacity of elements having channels of the same diameter maydiffer where one has fewer channels and the other has more channels—theformer having the higher adsorption capacity. One or more parameters maybe varied to achieve advantageous adsorption to an element of one (e.g.,selective adsorption) or more (e.g., semi-selective adsorption) speciescompared to 30 other species of the same polarity, according to someembodiments. Purification modules configured to perform selective and/orsemi-selective adsorption may be combined to produce one or more desiredsalts upon desorption of bound ions. For example, a desorption streamfrom a purification module configured and operated to selectively bindsodium ions may be combined with a desorption stream from a purificationmodule configured and operated to selectively bind chloride ions to forma solution comprising dissolved sodium chloride.

A ceramic element may exclude or include a membrane for removal ofparticles based on size. Element channels may have any desired size orarrangement. For example, all channels in an element may have the samesize and may be arranged in a regular pattern of rows and columns. Insome embodiments, each channel may have a diameter independent of otherchannels in the same element. Channels lined with a filter may be sizedor arranged with a view to managing the potential pressure drop acrossthe element when operated. Channels without a filtration layer may besized or arranged with a view to achieving a desired adsorptioncapacity.

The present disclosure relates, in some embodiments, to a ceramicmembrane. For example, a ceramic membrane may include a substrateconfigured to have a first surface and a second surface and body havingan average pore size of from about 3 μm to about 10 μm, from about 4 μmto about 9 μm, from about 5 μm to about 8 μm, and/or from about 6 μm toabout 7 μm. In some embodiments, a ceramic membrane may include amembrane layer on at least a portion of a first surface and/or a secondsurface of a membrane. A membrane layer may be configured to be as thinas possible or practicable to provide a desired or required filtrationcapacity at a desired TMP (e.g., the lowest TMP possible orpracticable). In some embodiments, multiple coats of a membrane layermay be contacted (i.e., applied) to a substrate. The number of coatscontacted to a substrate may depend on a desired pore size (i.e., eachlayer or coat being a smaller or larger pore size). Each membrane layermay be configured to provide a smaller pore size. In some embodiments,each membrane layer may be configured to provide a larger pore size.Iterative coating of membrane layers having a pore size gradient mayprevent a membrane layer from falling into a much larger substrate pore.In some embodiments, decreasing the average pore size of a substrate mayenhance support for a membrane layer. This additional support may bedisplayed in part by membrane layer material generally remainingsubstantially outside and above substrate pores. A thin membrane may, insome embodiments and under desired conditions, reduce impediments toflow of a fluid through a substrate. A membrane, in some embodiments,may be free of flow channels (channels an order of magnitude (or more)larger than the average pore size). A membrane may be configured to haveany desired geometric shape. For example, a membrane may be generallycylindrical. A membrane may have a generally hexagonal prismic shape.

Method of Use

The present disclosure relates, according to some embodiments, tomethods for using a purification system and/or apparatus. For example, apurification and/or filtration method may comprise (a) providing a mediacomprising contaminant solids, a dissolved salt anion, and a dissolvedsalt cation, (b) aggregating the contaminant solid into particles,and/or (c) removing the particles to form a first partially purifiedmedia. Aggregating dissolved contaminants may comprise contacting acontaminated media with a coagulant, a base, air (e.g., with an aerationunit), dissolved oxygen (e.g., with a dissolved oxygen unit), and/orother chemicals to permit and/or promote metal oxidation, reduction,chemical precipitation, chemical coagulation, or combinations thereof.In some embodiments, the final step—step (e)—may be omitted, forexample, if only charged species of one polarity (e.g., ammonia) are tobe removed.

In some embodiments, the present disclosure relates to methods for usinga purification system and/or apparatus. For example, a purificationand/or filtration method may comprise (a) providing a media comprising asuspended or dissolved contaminant and a dissolved salt, (b) filteringthe media on the basis of size to remove the suspended or dissolvedcontaminant to form a first partially purified media, (c) contacting thefirst partially purified media with a first substrate having a netcharge of a first polarity under conditions that permit oppositelycharged salt ions having a second polarity, opposite of the first, tobind to the first substrate to form a second partially purified media,and/or (d) optionally contacting the first partially purified media witha second substrate having a net charge of the second polarity underconditions that permit oppositely charged salt ions having the firstpolarity to bind to the second substrate to form a second partiallypurified media.

The present disclosure relates, according to some embodiments, tomethods for using a purification system and/or apparatus. For example, apurification and/or filtration method may comprise contacting acontaminated fluid with a filter (e.g., a ceramic filtration membrane).According to some embodiments, contacting a contaminated fluid with afilter (e.g., a ceramic filtration membrane) may include forming apermeate (e.g., fluid that passes through filter pores) and aconcentrate (e.g., fluid that does not pass through filter pores).

In some embodiments, a purification system, apparatus, and/or method maybe configured to operate, according to some embodiments, continuously,substantially continuously (e.g., continuously, but for briefmaintenance work), semi-continuously (e.g., less than 24 hours per day),periodically (e.g., over regular and/or irregular intervals), on demand,or combinations thereof. In some embodiments, a purification system,apparatus, and/or method may be operated to provide microfiltration,ultrafiltration, and/or nanofiltration of a subject fluid.

According to some embodiments, filtration may be conducted (e.g., afiltration module may be operated) with fewer or no periodic testing(e.g., QA/QC testing). For example, existing water filtration systemsmay have to be tested daily to assess and/or ensure membrane integrityand leak-free filtration. Configuration of a ceramic element accordingto some embodiments may alone provide at least the same level ofassurance without the need to test as frequently. For example, a ceramicelement configuration may provide an assurance of integrity by directcontinuous integrity testing through on line particle counter and/orturbidity measurement. A system according to some embodiments of thedisclosure may be operated continuously and without interruption forintegrity testing. For example, integrity assessments may be conductedduring operation.

A method may comprise operating a fluid purification system with anydesired throughput (e.g., contaminated media intake, permeate output,concentrate output, and/or combinations thereof), in some embodiments.For example, a method may be scalable to achieve a desired processingvolume by varying the number of membrane elements and/or varying thenumber of modules used.

A first ceramic element may be configured to selectively removeparticles on the basis of size. Optional second and third elements mayindependently be configured to selectively remove contaminants on thebasis of charge. In some embodiments, as fluid passes through anelement, negative ions adsorb onto the SiC substrate. Permeate may thenbe sent to a second element module with a negative charge to remove thecations. With a first element that provides filtration based on size(e.g., ultrafiltration), a membrane layer may not be required in any ofthe subsequent elements or modules. Omission of a membrane maydrastically reduce pressure drop.

Subsequent elements modules after the first one may be operated in adead-end mode. Cross flow may be desirable and/or required forfiltration applications; for example, it may provide shear to reducefouling. Once filtration is performed (e.g., in the firstelement/module), crossflow may not be required. Operating subsequentelements in a dead-end mode may reduce pump energy requirements. In someembodiments, dynamic shock (to reduce or eliminate membrane fouling) maybe applied to membranes, where present. For example, in a systemconfigured to reduce/remove solids in an initial filtration element andcharged particles (e.g., dissolved salts) in second and third elements,a dynamic shock may be applied to the first element. In someembodiments, applying a dynamic shock to all elements in a multi-elementsystem may provide a synergistic effect.

In some embodiments, a concentrate tank may be configured as a reactionvessel for metals oxidation, coagulation, hardness removal, and/orcombinations thereof. This functionality may be positioned on theconcentrate side of a membrane.

Methods of Making

According to some embodiments, methods of making a ceramic membrane maycomprise extruding, casting, or centrifugal casting a resilient materialinto the proper shape before firing. Membranes may comprise inorganicmaterials selected from alumina, zirconium dioxide, titanium dioxide, orsilicon carbide. A membrane may also be made by first preparing acarrier (i.e., substrate), and then applying the membrane to thecarrier. In this case, methods of making a membrane may comprise dippingthe carrier in a ceramic solution, and then treating with heat (i.e.,about 100 to about 2300° C.). In some embodiments, both the substratepreparation and membrane application steps may involve a heat treatment(i.e., about 100 to about 2300° C.). One or more additives may beincluded in a ceramic mixture, for example, to reduce firingtemperatures (which may in turn increase oven life span), and/or toincrease porosity, strength and/or charge of a substrate. A binder mayalso be added to a ceramic solution before it is treated with heat tohelp with mechanical properties comprising holding it into shape. Forexample, a binder comprises tylose, polyvinyl acetate, polypropylene,sodium polyacrylate, polypropylene carbonate, carboxymethylcellulose,starches, polyvinyl alcohol, dextrin, wax emulsions, polyethyleneglycols, lignosulfonates, paraffins, sodium silicate, magnesium aluminumsilicates, and bentonite.

Tylose, as a binder, improves the carrier by not cracking during initialdrying and heat treatment and also may provide a relatively smaller poresize (i.e., about 6 μM). A smaller pore size may afford mechanicaladvantages. For example, the smaller pore size may allow the membrane tobe applied without soaking into the carrier.

In some embodiments, to methods for making a ceramic membrane. Forexample, a method of making a ceramic membrane may include extruding asubstrate material comprising a binder, a lubricant, a defoamer, and/ora substrate base to form a length of extruded membrane substrate havingat least a first surface (e.g., an interior surface) and a secondsurface (e.g., an exterior surface). A binder may comprise, for example,a substance selected from tylose, polyvinyl acetate, polypropylene,sodium polyacrylate, polypropylene carbonate, carboxymethylcellulose,starches, polyvinyl alcohol, dextrin, wax emulsions, polyethyleneglycols, lignosulfonates, paraffins, sodium silicate, magnesium aluminumsilicates, and bentonite. A substrate base may comprise a substanceselected from alumina, zirconium dioxide, titanium dioxide, or siliconcarbide. In some embodiments, a first surface may define one or moreinner channels in an extruded ceramic membrane. A method may furthercomprise, according to some embodiments, drying and/or firing anextruded membrane substrate to form a ceramic membrane substrate. Amethod may further comprise contacting or applying a membrane layer toat least a portion of a first surface.

Filtration layer may wrap around both faces and partially cover thesides on each end of the filter. In FIG. 2B, ceramic element 257comprises channel 250, elongate side 255, first face 251, second face256, and substrate 253. As shown, ceramic element 257 has a generallyhexagonal prism shape with generally circular channels 250. Channels 250extend through ceramic element 257 along its length. A filtration layer252 is positioned over substrate 253. Outer filtration layer extendsfrom first face 251, along the sides to second face 256 as well ascompletely covering the inner surface of each channel 250. Filtrationlayer may wrap around both faces and partially cover the sides on eachend of the filter.

Example embodiments of a purification module are illustrated in FIG. 3.Purification module 320 comprises contaminated media chamber 322,permeate chamber 330, and concrete chamber 360. As shown, contaminatedmedia chamber 322 and permeate chamber 330 are secured to each otherwith a plurality of bolts and nuts. Concrete chamber 360 is similarlysecured to the distal end of permeate chamber 330. Contaminated mediachamber 322 comprises inlet 324, contaminated media chamber body 326,and flange 328. As shown, permeate chamber 330 comprises flanges 331,permeate chamber body 332, and outlet 333.

In operation, fluid-tight seals result in contaminated media movingthrough inlet 324 into a cavity defined by body 326, and into andthrough crossflow filters positioned in permeate chamber. Fluid thatpermeates the filters passes through permeate outlet 333. Fluid thatdoes not permeate the filters enters concentrate chamber 360.

Example embodiments of a permeate chamber with installed filterassemblies are illustrated in FIG. 4. As shown, a plurality offiltration assemblies 440 are inserted in apertures in the end plate ofpermeate chamber 430. Each ceramic element assembly 440 comprises anelongate ceramic element with gaskets 431 at each end. Ceramic elementassemblies 440 have been positioned in apertures in the end plate ofpermeate chamber 430 such that gaskets 441 form fluid-tight seals ateach end of permeate chamber 430. As shown, permeate chamber 430comprises permeate chamber body 432, and outlet 433.

Example embodiments of a permeate chamber with installed filterassemblies are illustrated in FIG. 5A. As shown, a plurality offiltration assemblies 540 are inserted in apertures in the end plate ofpermeate chamber 530. Each ceramic element assembly 540 comprises anelongate ceramic element with gaskets 531 at each end. Ceramic elementassemblies 540 have been positioned in apertures in the end plate ofpermeate chamber 530 such that gaskets 531 form fluid-tight seals ateach end of permeate chamber 430. As shown, permeate chamber 530comprises permeate chamber body 532, and outlet 533. As shown, anexample embodiment may comprise about 171 engaged ceramic membranes.

Example embodiments of a permeate chamber with installed filterassemblies are illustrated in FIG. 5B. As shown, a plurality offiltration assemblies 540 are inserted in apertures in the end plate ofpermeate chamber 530. Each ceramic element assembly 540 comprises anelongate ceramic element with gaskets 531 at each end. Ceramic elementassemblies 540 have been positioned in apertures in the end plate ofpermeate chamber 530 such that gaskets 531 form fluid-tight seals ateach end of permeate chamber 530. As shown, permeate chamber 530comprises permeate chamber body 532, and outlet 533. As shown, anexample embodiment may comprise about 36 engaged ceramic membranes.

According to some embodiments, a permeate chamber with installed filterassemblies are illustrated in FIG. 6A. As shown, a plurality offiltration assemblies 640 are inserted in apertures in the end plate ofpermeate chamber 630. Each ceramic element assembly 640 comprises anelongate ceramic element with gaskets 631 at each end. Ceramic elementassemblies 640 have been positioned in apertures in the end plate ofpermeate chamber 630 such that gaskets 631 form fluid-tight seals ateach end of permeate chamber 630. As shown, permeate chamber 630comprises outlet 633. As shown, an example embodiment may comprise about171 engaged ceramic membranes.

Example embodiments of a permeate chamber with installed filterassemblies are illustrated in FIG. 6B. As shown, a plurality offiltration assemblies 640 are inserted in apertures in the end plate ofpermeate chamber 630. Each ceramic element assembly 640 comprises anelongate ceramic element with gaskets 631 at each end. Ceramic elementassemblies 640 have been positioned in apertures in the end plate ofpermeate chamber 630 such that gaskets 631 form fluid-tight seals ateach end of permeate chamber 630. As shown, permeate chamber 630comprises outlet 633. As shown, an example embodiment may comprise about36 engaged ceramic membranes.

Specific example embodiments of a ceramic membrane is illustrated inFIG. 7. In FIG. 7, ceramic element 730 comprises channel 740, andpermeate channel 731. As shown, ceramic element 730 has generallycircular cross section with generally circular channels 740. Channels740 extend through ceramic element 730 along its length.

As will be understood by those skilled in the art who have the benefitof the instant disclosure, other equivalent or alternative compositions,devices, methods, and systems for fluid filtration can be envisionedwithout departing from the description contained herein. Accordingly,the manner of carrying out the disclosure as shown and described is tobe construed as illustrative only.

Persons skilled in the art may make various changes in the shape, size,number and/or arrangement of parts without departing from the scope ofthe instant disclosure. For example, the position and number of inlets,apertures, filters, gaskets, valves, pumps, sensors, and/or outlets maybe varied. In some embodiments, filters, seal gaskets, and/or filtrationassemblies may be interchangeable. Interchangeability may allow the sizeand/or kind of contaminates to be custom adjusted (e.g., by varying orselecting the pore size and/or kind of filter used). In addition, thesize of a device and/or system may be scaled up (e.g., to be used forhigh throughput commercial or municipal fluid filtration applications)or down (e.g., to be used for lower throughput household or researchapplications) to suit the needs and/or desires of a practitioner. Eachdisclosed method and method step may be performed in association withany other disclosed method or method step and in any order according tosome embodiments. Where the verb “may” appears, it is intended to conveyan optional and/or permissive condition, but its use is not intended tosuggest any lack of operability unless otherwise indicated. Personsskilled in the art may make various changes in methods of preparing andusing a composition, device, and/or system of the disclosure. Forexample, a composition, device, and/or system may be prepared and orused as appropriate for animals and/or humans (e.g., with regard tosanitary, infectivity, safety, toxicity, biometric, and otherconsiderations). Elements, compositions, devices, systems, methods, andmethod steps not recited may be included or excluded as desired orrequired.

Also, where ranges have been provided, the disclosed endpoints may betreated as exact and/or approximations as desired or demanded by theparticular embodiment. Where the endpoints are approximate, the degreeof flexibility may vary in proportion to the order of magnitude of therange. For example, on one hand, a range endpoint of about 50 in thecontext of a range of about 5 to about 50 may include 50.5, but not 52.5or 55 and, on the other hand, a range endpoint of about 50 in thecontext of a range of about 0.5 to about 50 may include 55, but not 60or 75. In addition, it may be desirable in some embodiments to mix andmatch range endpoints. Also, in some embodiments, each figure disclosed(e.g., in one or more of the examples, tables, and/or drawings) may formthe basis of a range (e.g., depicted value+/−about 10%, depictedvalue+/−about 50%, depicted value+/−about 100%) and or a range endpoint.With respect to the former, a value of 50 depicted in an example, table,and/or drawing may form the basis of a range of, for example, about 45to about 55, about 25 to about 100, and/or about 0 to about 100.Disclosed percentages are weight percentages except where indicatedotherwise.

All or a portion of a device and/or system for fluid filtration may beconfigured and arranged to be disposable, serviceable, interchangeable,and/or replaceable. These equivalents and alternatives along withobvious changes and modifications are intended to be included within thescope of the present disclosure. Accordingly, the foregoing disclosureis intended to be illustrative, but not limiting, of the scope of thedisclosure as illustrated by the appending claims.

The title, abstract, background, and headings are provided in compliancewith regulations and/or for the convenience of the reader. They includeno admissions as to the scope and content of prior art and nolimitations appreciable to all disclosed embodiments.

What is claimed is:
 1. A ceramic membrane comprising: a substratecomprising a binder and having a first face, a second face, one or moreinner channels, and an elongate side connecting the first face to thesecond face; a first membrane layer on at least a portion of the firstface of the substrate; and a second membrane layer on at least a portionof the second face of the substrate; and a third membrane layer on atleast a portion of the one or more inner channels, wherein the ceramicmembrane is configured to have a clean water flux of about 2000 litersper hour per square meter of membrane surface area at a transmembranepressure of about 20 psi or less, wherein the binder comprises asubstance selected from the group consisting of tylose, polypropylene,sodium polyacrylate, polypropylene carbonate, carboxymethylcellulose,starches, dextrin, wax emulsions, lignosulfonates, paraffins, sodiumsilicate, magnesium aluminum silicates, and bentonite, and wherein: eachof the first membrane layer, the second membrane layer, and the thirdmembrane layer comprises a larger pore size than the substrate, or eachof the first membrane layer, the second membrane layer, and the thirdmembrane layer comprises a smaller pore size than the substrate.
 2. Theceramic membrane according to claim 1, wherein the substrate furthercomprises a substrate base selected from the group consisting ofalumina, zirconium dioxide, titanium dioxide, and silicon carbide. 3.The ceramic membrane according to claim 1, wherein the ceramic membraneis configured to have a transmembrane pressure of about 20 psi or lessat about 20° C.
 4. The ceramic membrane according to claim 1, whereinthe substrate has an average pore size from about 3 μm to about 10 μm.5. The ceramic membrane according to claim 1, wherein each of the firstface and the second face of the ceramic membrane has a diameter fromabout 38 mm to about 90 mm.
 6. The ceramic membrane according to claim1, wherein the ceramic membrane is a hexagonal prism.
 7. The ceramicmembrane according to claim 1, wherein each of the first face and thesecond face of the ceramic membrane has a diameter of about 80 mm. 8.The ceramic membrane according to claim 1, wherein the ceramic membranehas a length from about 800 mm to about 1600 mm.
 9. The ceramic membraneaccording to claim 1, wherein the first membrane layer comprises asubstance selected from the group consisting of alumina, zirconiumdioxide, titanium dioxide, and silicon carbide.
 10. The ceramic membraneaccording to claim 1, wherein the second membrane layer comprises asubstance selected from the group consisting of alumina, zirconiumdioxide, titanium dioxide, and silicon carbide.
 11. The ceramic membraneaccording to claim 1, wherein the third membrane layer comprises asubstance selected from the group consisting of alumina, zirconiumdioxide, titanium dioxide, and silicon carbide.
 12. The ceramic membraneaccording to claim 1, wherein up to three coats of the first membranelayer contact at least a portion of the first surface of the ceramicmembrane.
 13. The ceramic membrane according to claim 1, wherein up tothree coats of the second membrane layer contact at least a portion ofthe second surface of the ceramic membrane.
 14. The ceramic membraneaccording to claim 1, wherein up to three coats of the third membranelayer contact at least a portion of the one or more inner channels. 15.The ceramic membrane of claim 1, wherein each of the first membranelayer, the second membrane layer, and the third membrane layer comprisesa first coat on at least a portion of the substrate, a second coat ontop of the first coat, and a third coat on top of the second coat. 16.The ceramic membrane of claim 15, wherein: the third coat has a smallerpore size than the second coat and the second coat has a smaller poresize than the first coat, or the third coat has a larger pore size thanthe second coat and the second coat has a larger pore size than thefirst coat.
 17. A ceramic membrane comprising: a substrate comprising abinder and having a first face, a second face, and an elongate bodycomprising one or more inner channels that each extend through thesubstrate along its length and open at the first face and the secondface, the elongate body connecting the first face to the second face; afirst membrane layer on at least a portion of the first face of thesubstrate; a second membrane layer on at least a portion of the secondface of the substrate; and a third membrane layer on at least a portionof the one or more inner channels, wherein the ceramic membrane isconfigured to have a clean water flux of about 2000 liters per hour persquare meter of membrane surface area at a transmembrane pressure ofabout 20 psi or less, wherein the binder comprises a substance selectedfrom the group consisting of tylose, polypropylene, sodium polyacrylate,polypropylene carbonate, carboxymethylcellulose, starches, dextrin, waxemulsions, lignosulfonates, paraffins, sodium silicate, magnesiumaluminum silicates, and bentonite, wherein the substrate comprises apore size from about 3 μm to about 10 μm, wherein the ceramic membranehas a length from about 800 mm to about 1,600 mm, and wherein: each ofthe first membrane layer, the second membrane layer, and the thirdmembrane layer comprises a larger pore size than the substrate, or eachof the first membrane layer, the second membrane layer, and the thirdmembrane layer comprises a smaller pore size than the substrate.
 18. Theceramic membrane of claim 17, wherein each of the first membrane layer,the second membrane layer, and the third membrane layer comprises afirst coat on at least a portion of the substrate, a second coat on topof the first coat, and a third coat on top of the second coat.
 19. Theceramic membrane of claim 17, wherein: the third coat has a smaller poresize than the second coat and the second coat has a smaller pore sizethan the first coat, or the third coat has a larger pore size than thesecond coat and the second coat has a larger pore size than the firstcoat.
 20. The ceramic membrane of claim 17, wherein one or more of: eachof the first face and the second face of the ceramic membrane has adiameter from about 38 mm to about 90 mm, the ceramic membrane is ahexagonal prism, and the ceramic membrane has a length from about 800 mmto about 1600 mm.